US20070017329A1 - Punching die for manufacturing a holding seal member, and method for manufacturing a holding seal member with a punching die - Google Patents

Punching die for manufacturing a holding seal member, and method for manufacturing a holding seal member with a punching die Download PDF

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Publication number
US20070017329A1
US20070017329A1 US11/400,780 US40078006A US2007017329A1 US 20070017329 A1 US20070017329 A1 US 20070017329A1 US 40078006 A US40078006 A US 40078006A US 2007017329 A1 US2007017329 A1 US 2007017329A1
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United States
Prior art keywords
punching
holding seal
fiber mat
punching die
blades
Prior art date
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Abandoned
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US11/400,780
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English (en)
Inventor
Shiro Osumi
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Ibiden Co Ltd
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Ibiden Co Ltd
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Assigned to IBIDEN CO., LTD. reassignment IBIDEN CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: OSUMI, SHIRO
Publication of US20070017329A1 publication Critical patent/US20070017329A1/en
Abandoned legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/022—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
    • B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
    • B26F1/38—Cutting-out; Stamping-out
    • B26F1/44—Cutters therefor; Dies therefor
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
    • B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
    • B26F1/38—Cutting-out; Stamping-out
    • B26F1/40—Cutting-out; Stamping-out using a press, e.g. of the ram type
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
    • B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
    • B26F1/38—Cutting-out; Stamping-out
    • B26F1/44—Cutters therefor; Dies therefor
    • B26F2001/4472—Cutting edge section features
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T83/00—Cutting
    • Y10T83/04—Processes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T83/00—Cutting
    • Y10T83/869—Means to drive or to guide tool
    • Y10T83/8821—With simple rectilinear reciprocating motion only

Definitions

  • the present invention relates to a punching die for use in manufacturing a holding seal member for winding around an exhaust gas purifier body, and to a manufacturing method for a holding seal member employing such a punching die.
  • An exhaust gas treatment apparatus for use in a vehicle is normally located in the middle of an exhaust passage in a vehicle.
  • a diesel particulate filter (DPF) and an exhaust gas purifying catalyst converter, which removes graphite particles referred to as particulates, are known in the prior art as examples of an exhaust gas treatment apparatus.
  • a typical exhaust gas treatment apparatus includes an exhaust gas purifier body, a metal pipe (shell) enclosing the exhaust gas purifier body, and a holding seal member filling the gap between the exhaust gas purifier body and the metal pipe.
  • the holding seal member must function to prevent the exhaust gas purifier body from being broken when hit against the metal pipe due to vibrations of the vehicle.
  • the holding seal member must also function to prevent the exhaust gas purifier body from falling off from the metal pipe or dislodging in the metal pipe when subjected to exhaust gas pressure. Further, the holding seal member must prevent the exhaust gas from leaking out of the gap between the metal pipe and the exhaust gas purifier body.
  • a conventional holding seal member is produced by cutting a fiber mat having a uniform thickness (refer to JP-A-2001-316965). Scissors, knives, or punching blades (Thomson blades) are used for cutting the fiber mat.
  • One aspect of the present invention is a punching die for punching a sheet of an inorganic fiber mat to manufacture a holding seal member for winding around an exhaust gas purifier body.
  • the punching die includes a base plate.
  • a further aspect of the present invention relates to a method for manufacturing a holding seal member for winding around an exhaust gas purifier body from a sheet of inorganic fiber mat.
  • the method includes forming a punching die by supporting a double-edged punching blade on a base plate, and using the punching die to punch the inorganic fiber mat to form a holding seal member.
  • the punching blade includes two side surfaces, two inclination surfaces inclined relative to the two side surfaces, and a cutting edge defined between the two inclined surfaces.
  • the two inclined surfaces are inclined at the same or different inclination angles.
  • the inclination angles of the two inclined surfaces are both about ten to about thirty degrees.
  • the difference between the inclination angles of the two inclined surfaces is about ten degrees or less.
  • the punching blade is made of carbon steel.
  • the inorganic fiber mat is made of alumina fibers.
  • the punching blade is lattice-shaped and cuts out a plurality of holding seal members from the inorganic fiber mat in a single punch.
  • the punching blade includes a plurality of parallel and straight longitudinal blades, a plurality of lateral blades intersecting the longitudinal blades at a right angle and bent to form a tab and a socket for receiving the tab in each of the holding seal members.
  • the longitudinal blades and the lateral blades are welded together.
  • the plurality of longitudinal blades and the plurality of lateral blades have the same height.
  • FIG. 1A is a bottom view of a punching die according to a preferred embodiment of the present invention.
  • FIG. 1B is a partially enlarged view of FIG. 1A ;
  • FIG. 2 is a cross-sectional view taken along line 2 - 2 in FIG. 1A .
  • FIG. 3A is an enlarged view showing a symmetric cutting edge
  • FIG. 3B is an enlarged view showing an asymmetric cutting edge
  • FIGS. 4A to 4 D are cross-sectional views showing the punching of an inorganic fiber mat with the punching die shown in FIG. 1A ;
  • FIG. 5 is a partially cutaway perspective view of an exhaust gas purifier assembly having a holding seal member of the preferred embodiment.
  • the punching die 11 includes a base plate 12 , a plurality of punching blades 13 supported by the base plate 12 , and elastic members 14 attached to the base plate 12 .
  • the elastic members 14 are elastically deformed in a reversible manner when pressed.
  • the punching die 11 punches a sheet of an inorganic fiber mat 16 to cut out a holding seal member 15 for winding around a filter member 42 , which functions as an exhaust gas purifier body.
  • the punching die 11 of the preferred embodiment cuts out a plurality of holding seal members 15 from a sheet of inorganic fiber mat 16 .
  • the holding seal member 15 is strip-shaped and has a tab 15 b and a socket 15 a .
  • the holding seal member 15 has a uniform thickness.
  • the inorganic fiber mat 16 has a uniform thickness and is formed from a felt or nonwoven fabric having a uniform resilience.
  • the inorganic fiber mat 16 is preferably made of ceramic fibers such as silica fibers, alumina fibers, mixed fibers of silica and alumina, and glass fibers.
  • the inorganic fiber mat 16 may be impregnated with an organic binder before the cutting to give the mat a predetermined thickness and repulsive force.
  • the organic binder may be a water-soluble resin such as acrylic resin or polyvinyl alcohol, or latex such as acrylic rubber or nitrile rubber.
  • the thickness of the holding seal member 15 is determined in accordance with the type of the inorganic fiber mat 16 , the type of catalyst carrier, and the type of exhaust gas purifier body.
  • the inorganic fiber mat 16 may be needle-punched for reducing bulkiness (thickness).
  • the base plate 12 is made of wood or plywood such as veneer.
  • the base plate 12 has a processing surface 12 a .
  • the punching blades 13 project orthogonally from the processing surface 12 a .
  • the processing surface 12 a of the base plate 12 is arranged in parallel with a support table 17 supporting the inorganic fiber mat 16 during the punching operation.
  • the base plate 12 reciprocates toward and away from the support table 17 .
  • the punching blades 13 cut out a plurality of holding seal members 15 from the inorganic fiber mat 16 , which is located at a punching area S, through a single punching operation.
  • the size of the base plate 12 is determined in accordance with the size of the punching area S.
  • Blade grooves 12 b are formed in the processing surface 12 a of the base plate 12 to receive the basal ends 13 b of the punching blades 13 .
  • the blade grooves 12 b are formed through, for example, laser processing.
  • the punching blades 13 are fabricated by bending a metal band in accordance with the shape of the holding seal members 15 .
  • the punching blades 13 each have a cutting edge 13 a shaped in accordance with the holding seal member 15 and a basal end 13 b inserted into the blade groove 12 b .
  • the punching blades 13 are, for example, lattice-shaped and include connection end formation blades (lateral blades) 18 , which form the sockets 15 a and tabs 15 b of the holding seal members 15 , side formation blades (longitudinal blades) 19 , which form longitudinal sides of the holding seal members 15 .
  • Each lateral blade 18 has a cutting edge which is bent in accordance with the shape of the sockets 15 a and the tabs 15 b .
  • Each longitudinal blade 19 has a linear, straight cutting edge.
  • the lateral blades 18 and the longitudinal blades 19 are welded together at a plurality of joints 13 f .
  • each lateral blade 18 forms a connection end, or a socket 15 a , in one of two adjacent holding seal members 15 , and a connection end, or a tab 15 b , in the other one of the two adjacent holding seal members 15 .
  • Each longitudinal blade 19 forms the longitudinal sides of two adjacent holding seal members 15 at the same time.
  • a plurality of holding seal members 15 and the remaining peripheral portion are cut out from a sheet of inorganic fiber mat 16 by the punching blades 13 .
  • thirty-six holding seal members 15 may be formed simultaneously.
  • the thickness of the punching blades 13 is not limited to any specific value, the thickness is about 0.5 through about 1.5 mm, preferably about 0 . 8 through about 1.2 mm, and more preferably about 1.0 mm.
  • the punching blades 13 have high durability and resist breakage when having a thickness of about 0.5 mm or more. When the thickness is about 1.5 mm or less, the punching blades 13 may easily be formed by bending a metal band without affecting the shape of the holding seal members 15 . Each cut-out holding seal member 15 will not be caught tightly between the punching blades 13 enclosing each holding seal member 15 if the punching blades 13 have the proper thickness.
  • the cut-out holding seal members 15 can be easily pushed out of the punching die 11 by the elastic members 14 .
  • the height (h) from the processing surface 12 a of the base plate 12 to the cutting edge 13 a of each punching blade 13 is determined in accordance with the thickness and material of the holding seal members 15 .
  • the punching blade 13 which is double-edged, includes two side surfaces 13 e 1 and 13 e 2 , two inclined surfaces 13 c and 13 d respectively inclined to the two side surfaces 13 e 1 and 13 e 2 , and a cutting edge 13 a defined by the two inclined surfaces 13 c and 13 d .
  • the two inclined surfaces 13 c and 13 d are respectively inclined at inclination angles ⁇ 1 and ⁇ 2 .
  • the inclination angles ⁇ 1 and ⁇ 2 are the same or about the same. More specifically, the difference between the inclination angles ⁇ 1 and ⁇ 2 is about ten degrees or less, preferably about five degrees of less, and more preferably about zero degrees.
  • FIG. 3B shows a punching blade 13 in which inclination angle ⁇ 3 is less than inclination angle ⁇ 4 .
  • the cutting edge 13 a is deviated from a center line T of the cutting edge 13 a toward the side surface 13 e 1 (the side surface of which inclination angle is small). In this case, the punching load applied to the cutting edge 13 a differs between the side of the inclined surface 13 c and the side of the inclined surface 13 d.
  • the inclination angles ⁇ 1 and ⁇ 2 are preferably about 10 to about 30 degrees, preferably about 15 to about 25 degrees, and more preferably about 17 to about 22 degrees. As long as the inclination angles ⁇ 1 and ⁇ 2 are about 10 degrees or greater, the cutting edge 13 a would not be too sharp or too thin. Thus, the application of load produced when punching the inorganic fiber mat 16 having a predetermined thickness and repulsion force would not damage the cutting edge 13 a . Further, as long as the inclination angles ⁇ 1 and ⁇ 2 are about 30 degrees or less, the cutting edge 13 a is sharp enough to completely cut the inorganic fiber mat 16 . Also, the cutting edge 13 a would not be damaged when receiving the load produced when punching the inorganic fiber mat 16 . As long as the inclination angle is within the above range, the inclination angles ⁇ 1 and ⁇ 2 may be the same or different.
  • Examples of material for the punching blade 13 include steels such as carbon steel, stainless steel, molybdenum steel, and special steel (alloy steel); alloys such as cobalt alloy (stellite), and titanium alloy; and fine ceramics such as zirconia and alumina. Steels that can be heat treated to increase hardness are preferable. Particularly, carbon steel is preferable since it has a relatively high hardness and durability and can easily be obtained. Further, the mechanical characteristics of carbon steel may be varied in accordance with its purpose of use by changing the content rate of carbon. Carbon steel is an alloy of steel and carbon and has a carbon (C) content rate of 2% or less. Further, carbon steel contains a slight amount of silicon, manganese, phosphor, and sulfur.
  • C carbon
  • Carbon steel is classified into dead soft steel having a carbon content rate of about 0.12% or less, low carbon steel (soft steel) having a carbon content rate of about 0.12% to about 0.2%, medium carbon steel (semi-soft steel, semi-hard steel) having a carbon content rate of about 0.2% to about 0.45%, high carbon steel (hard steel) having a carbon content rate of about 0.45% to about 0.8%, and extra hard steel having a carbon content rate of about 0.8 to about 1.7%.
  • a higher carbon content rate increases the hardness that is obtained through heat treatment.
  • a lower carbon content rate increases rust resistance.
  • the amount of carbon in carbon steel is determined in accordance with the material and purpose of the inorganic fiber mat 16 .
  • the punching blade 13 may be manufactured from a grad material obtained by bonding a plurality of metal materials.
  • carbon steel having a high carbon content rate may be selectively used for the cutting edge 13 a .
  • the cutting edge 13 a that is obtained is hard.
  • Layers of carbon steel having a low carbon content rate may be laminated on the two side surfaces 13 e 1 and 13 e 2 .
  • Such a triple layer structure would improve the rust resistance of the punching blade 13 .
  • Carbon steel having a low carbon content rate may be used at bent portions of the punching blade 13 . This would enable easy bending of the punching blade 13 and facilitate manufacturing. If the inorganic fiber mat 16 is made of alumina fibers, it is preferable that carbon steel having a high carbon content rate be used as the material of the punching blade 13 .
  • the elastic members 14 are attached to the processing surface 12 a of the base plate 12 .
  • the elastic members 14 push out each holding seal member 15 enclosed and held by the punching blades 13 towards the support table 17 when the punching blades 13 are moved away from the support table 17 .
  • the elastic members 14 are elastic layers having a uniform thickness (t).
  • the thickness (t) is preferably greater than the height (h) of the punching blades. If the thickness (t) of the elastic members 14 is less than the height (h) of the punching blades 13 , wear will occur in the elastic members 14 due to repetitive punching operations. In such a case, the holding seal members 15 will not be sufficiently pushed out.
  • the thickness of the elastic members 14 should be varied in accordance with the thickness of the holding seal members 15 and the height of the punching blades 13 .
  • the thickness of the elastic members 14 is set to about 10 mm or less, and more preferably, to about 3 to about 7 mm.
  • the material for the elastic members 14 is not especially limited as long as it is an elastic material that is elastically deformed in a reversible manner when pressed.
  • the material for the elastic members 14 may be nonwoven fabric or felt made of organic or inorganic fibers, or foam made of an expandable material. When using foam, fibers do not become entangled in the holding seal members.
  • Foams usable for the elastic members 14 include polyurethane foam, polyester foam, melamine resin foam, phenolic resin foam, polyethylene foam, polypropylene foam, polystyrene foam, natural rubber foam, synthetic rubber foam, and elastomeric foam.
  • the elastic members 14 may be made from either a single elastic material or a combination of two or more elastic materials.
  • the elastic members 14 may be made of either a single layer or laminated layers of the same or different elastic materials.
  • the present inventors have checked the wear rate for various elastic materials.
  • the wear rate for each elastic material was computed by measuring the reduction percentage in compression load before and after the elastic material was compressed and decompressed repeatedly for 100 times. A low wear rate indicates that the material is restorable to its original shape.
  • the results show that synthetic rubber foam exhibited the lowest wear rate when subjected to the repeated compression. Consequently, it is most preferable that the elastic members 14 be made of synthetic rubber foam. It is preferable that the wear rate of the elastic members 14 be lower.
  • the wear rate for synthetic rubber foam was about 2% or less. An elastic material having a high wear rate will be compressed in an irreversible manner through successive punching operations. Thus, the holding seal members 15 will not be sufficiently pushed out.
  • the compression load deflection at 25% for the elastic members 14 is about 25 through about 120 kPa, preferably about 30 through about 100 kPa, and more preferably about 40 through about 60 kPa.
  • the compression load deflection at 25% was measured in accordance with American Society For Testing and Materials (ASTM) D1056.
  • Elastic members having a compression load deflection at 25% of about 25 to about 120 kPa will generate enough repulsive force to push out the holding seal members 15 held by the punching blades 13 and will be soft enough so that it does not change the characteristics or shape of the holding seal members 15 during punching.
  • the punching blades 13 define a plurality of partitioned sections, each having the shape of the holding seal members 15 .
  • the elastic members 14 are arranged within the partitioned sections on the processing surface 12 a of the base plate 12 .
  • the elastic members 14 are also arranged at the outer side of the punching blades 13 on the processing surface 12 a .
  • the elastic members 14 located in the partitioned sections function to push out the holding seal members 15 , which have been pressed into the partitioned sections, from the punching die 11 .
  • the elastic member 14 located outside the punching blades 13 push out the peripheral portion of the punched inorganic fiber mat 16 from the punching die 11 .
  • the elastic members 14 are adhered to substantially the entire processing surface 12 a , except for where the punching blades 13 are located, with a two-sided adhesive tape or an adhesive agent. As shown in FIG. 2 , the elastic members 14 preferably do not contact the punching blade 13 . Preferably, each of the elastic members 14 is separated from the side surface of the punching blade 13 by a distance of about zero to about 10 mm to define gap 20 therebetween. If the gap 20 is about 10 mm or greater, the holding seal members 15 will be apt to catch in the gap 20 and will become difficult to be forced out of the gap 20 . This may result in deformation of the holding seal members 15 .
  • the gap 20 is greater than about zero mm, the repulsive force of the elastic member 14 would not be reduced by frictional resistance between the side surface of elastic member 14 and the side surface of the punching blade 13 . More preferably, the gap 20 is about five 5 mm. If the gap 20 is about five mm, the repulsive force of the elastic member 14 would not be reduced by frictional resistance between the side surfaces of the elastic member 14 and the punching blade 13 . Moreover, the repulsive force of the elastic member 14 will act on substantially the entire surface of the holding seal member 15 .
  • An inorganic fiber mat 16 having a predetermined thickness and repulsive force is placed on the support table 17 .
  • the inorganic fiber mat 16 is positioned in the punching area S of the punching die 11 .
  • the punching die 11 is lowered while being kept parallel with the support table 17 ( FIG. 4A ).
  • the elastic members 14 first come into contact with the inorganic fiber mat 16 .
  • the inorganic fiber mat 16 is thus held between the elastic members 14 and the support table 17 .
  • the elastic members 14 are compressed and the cutting edges 13 a of the punching blades 13 come into contact with the upper surface of the inorganic fiber mat 16 .
  • the punching die 11 when the punching die 11 is further lowered, the cutting edges 13 a of the punching blades 13 come into contact with the support table 17 and the holding seal members 15 are cut out from the inorganic fiber mat 16 .
  • the holding seal members 15 are pressed into the partitioned sections and compressed for an amount corresponding to the thickness of the punching blades 13 .
  • the punching die 11 is raised ( FIG. 4C )
  • the holding seal members 15 are pushed out (released) from the partitioned sections by the repulsive force of the elastic members 14 .
  • the cutting edges 13 a of the punching blades 13 have been moved away from the inorganic fiber mat 16 .
  • the inorganic fiber mat 16 is still held between the elastic members 14 and the support table 17 .
  • the punching die 11 is further raised until the elastic members 14 are moved away from the inorganic fiber mat 16 ( FIG. 4D ).
  • the support table 17 is then conveyed to the next process.
  • the lowering and raising of the punching die 11 may be performed in cooperation with the movement of a belt conveyor conveying the support table 17 . In this case, the punching die 11 may consecutively punch the inorganic fiber mat 16 .
  • a holding seal member 15 is wound around an exhaust gas purifier body such as a catalyst carrier 21 .
  • the tab 15 b is fitted in the socket 15 a of the holding seal member 15 .
  • the holding seal member 15 can be wound around the entire circumference of the catalyst carrier 21 without the ends of the holding seal member 15 overlapping each other.
  • the catalyst carrier 21 to which the holding seal member 15 is wound around, is pressed into a tubular metal shell 23 .
  • the holding seal member 15 is elastically compressed when pressed into the tubular shell 23 .
  • the catalyst carrier 21 is held in the tubular shell 23 by the repulsive force of the holding seal member 15 .
  • the holding seal member 15 also functions as a protective cushion preventing the catalyst carrier 21 from being hit against the tubular shell 23 by vibrations transmitted from the outer side.
  • the preferred embodiment has the advantages described below.
  • the punching blade 13 is a double-edged blade having a cutting edge 13 a defined between the inclined surfaces 13 c and 13 d respectively inclined to the two side surfaces 13 e 1 and 13 e 2 .
  • the cutting edge 13 a resists deformation and the punching blade 13 has high durability.
  • the difference between the inclination angles ⁇ 1 and ⁇ 2 of the inclined surfaces 13 c and 13 d is about ten degrees or less. This prevents the punching load acting on the cutting edge 13 a from differing greatly between the side of the inclined surface 13 c and the side of the inclined surface 13 d .
  • the punching blade 13 has sufficient durability for consecutively cutting out holding seal members 15 .
  • the cutting edge 13 a is located at a generally median position T with respect to the thickness of the punching blade 13 .
  • the punching blade 13 has a high cutting accuracy and cuts out two adjacent holding seal members 15 with the same dimensions and shapes.
  • the punching blade 13 has superior hardness and durability.
  • the inorganic fiber mat 16 which is bulky and made of alumina fibers, produces sufficient repulsive force for holding a catalyst carrier.
  • the use of carbon steel having a high carbon content rate and thus having superior durability and hardness is especially effective for the consecutive punching of such an inorganic fiber mat 16 .
  • the inorganic fiber mat 16 placed on the support table 17 is positioned to face the punching blades 13 immediately before a punching operation. This prevents production of defective holding seal members.
  • the blade grooves 12 b may easily be formed.
  • a holding seal member 15 cut out by the punching die 11 has uniform cut surfaces and a uniform thickness.
  • the socket 15 a and the tab 15 b are identically shaped. This manufactures the holding seal member 15 so that it perfectly fits into the catalyst carrier 21 .
  • the preferred embodiment may be modified as described below.
  • the base plate 12 may be made of a metal material.
  • the blade grooves 12 b may be formed partially or entirely in the processing surface 12 a of the base plate 12 in correspondence with the punching blades 13 .
  • the punching blades 13 may each be fastened to the base plate 12 by a fastener such as a screw or a bolt.
  • a through hole may be formed in the base plate 12 to communicate with the blade groove 12 b .
  • the stability and durability of the punching blade 13 would be improved by inserting part of the punching blade 13 into the through hole.
  • the support table 17 may be raised and lowered instead of the punching die 11 .
  • the inclined surfaces 13 c and 13 d of the punching blade 13 may be formed by performing a known grinding method using a grinding stone or a lathe to grind an edge of a metal belt.
  • the punching blade 13 is not limited to the illustrated double-edged blade and may be a two-step blade having inclined surfaces 13 c and 13 d inclined in a stepped manner for two inclination angles. Further, the cutting edge 13 a may be chamfered within a range that the cutting characteristics are not affected.
  • the punching die 11 may be cut out one or more holding seal members 15 from a single sheet of inorganic fiber mat 16 .
  • the material for the support table 17 is not limited. Any material may be used as long as it is capable of supporting the inorganic fiber mat 16 in parallel and does not damage the cutting edges 13 a .
  • the material for the support table 17 may be, for example, a laminated body of a resin such as polypropylene resin, rubber, foam, or fibers, or a laminated body coated with such resin, rubber, foam, or fibers.
  • the holding seal member 15 may also be wound around a diesel particulate filter (DPF) in addition to the catalyst carrier 21 .
  • DPF diesel particulate filter
  • the inclination angles ⁇ 1 and ⁇ 2 may be the same or different at different positions along the cutting edge 13 a.
  • Blades having inclination angles ⁇ 1 and ⁇ 2 shown in table 1 were fixed to the base plate 12 to prepare the punching dies of test examples 1 to 6.
  • the blade thickness was one millimeter.
  • the durability of the punching die blades in test examples 1 to 6 was measured by carrying out the process described below.
  • the alumina fiber mat 16 was placed on the support table 17 and punched by each of the test examples 1 to 6 with the same pressure. The punching was repeated until at least one of the next abnormalities occurred.
  • the abnormalities were categorized into abnormality 1—blade chipping or blade deformation, abnormality 2—imperfect cutting of holding seal member, and abnormality 3—difference between dimension of punched out holding seal member and initial dimension being one millimeter or greater (dimensional abnormality). The number of times of consecutive punching until the occurrence of an abnormality was counted. The results are shown in table 1.
  • JP-A-2001-316965 The contents of JP-A-2001-316965 are incorporated herein by reference.

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  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Perforating, Stamping-Out Or Severing By Means Other Than Cutting (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Encapsulation Of And Coatings For Semiconductor Or Solid State Devices (AREA)
US11/400,780 2005-07-25 2006-04-06 Punching die for manufacturing a holding seal member, and method for manufacturing a holding seal member with a punching die Abandoned US20070017329A1 (en)

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JP2005215053A JP2007031867A (ja) 2005-07-25 2005-07-25 排ガス処理体の保持シール材用打抜板及びそれを用いた保持シール材の製造方法

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US (1) US20070017329A1 (ja)
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US20070017328A1 (en) * 2005-07-19 2007-01-25 Shiro Osumi Punching die for manufacturing seal member and method for manufacturing seal member
US20070017327A1 (en) * 2005-07-19 2007-01-25 Shiro Osumi Punching die for manufacturing seal member and method for manufacturing seal member
US20070028744A1 (en) * 2005-07-25 2007-02-08 Shiro Osumi Punching die for manufacturing exhaust gas purifier holding seal member and method for manufacturing holding seal member with punching die
US20100084219A1 (en) * 2007-03-06 2010-04-08 Uwe Troeger Muffler insulating element, muffler and method of producing a muffler
US20180236683A1 (en) * 2017-02-23 2018-08-23 Seoul Laser Dieboard System Co., Ltd. Dieboard padding
CN111549520A (zh) * 2020-05-21 2020-08-18 海盐新福莱防水面料股份有限公司 一种高耐磨牛津布裁切装置

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JP5084466B2 (ja) * 2007-11-21 2012-11-28 住友電気工業株式会社 光ファイバ切断用カッター、光ファイバの切断方法および光ファイバ切断用カッターを備えた光ファイバ切断機
WO2011038377A1 (en) * 2009-09-28 2011-03-31 Tek Industries, Inc. Die cut with common blades
CN102172925A (zh) * 2011-01-07 2011-09-07 天津普瑞特产品标识有限公司 模切刀及其制作方法
CN103722589B (zh) * 2012-10-12 2016-12-21 珠海格力电器股份有限公司 百叶窗模具
CN105196353A (zh) * 2014-06-24 2015-12-30 嘉联益科技股份有限公司 冲切刀具

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Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20070017328A1 (en) * 2005-07-19 2007-01-25 Shiro Osumi Punching die for manufacturing seal member and method for manufacturing seal member
US20070017327A1 (en) * 2005-07-19 2007-01-25 Shiro Osumi Punching die for manufacturing seal member and method for manufacturing seal member
US8042440B2 (en) 2005-07-19 2011-10-25 Ibiden Co., Ltd. Punching die for manufacturing seal member and method for manufacturing seal member
US20070028744A1 (en) * 2005-07-25 2007-02-08 Shiro Osumi Punching die for manufacturing exhaust gas purifier holding seal member and method for manufacturing holding seal member with punching die
US20100084219A1 (en) * 2007-03-06 2010-04-08 Uwe Troeger Muffler insulating element, muffler and method of producing a muffler
US20180236683A1 (en) * 2017-02-23 2018-08-23 Seoul Laser Dieboard System Co., Ltd. Dieboard padding
US11235488B2 (en) * 2017-02-23 2022-02-01 Seoul Laser Dieboard System Co., Ltd. Dieboard padding
CN111549520A (zh) * 2020-05-21 2020-08-18 海盐新福莱防水面料股份有限公司 一种高耐磨牛津布裁切装置

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EP1747863B1 (en) 2008-09-10
CN1904196A (zh) 2007-01-31
EP1747863A1 (en) 2007-01-31
ATE408055T1 (de) 2008-09-15
KR100870079B1 (ko) 2008-11-25
KR20070013201A (ko) 2007-01-30
KR20080019681A (ko) 2008-03-04
DE602006002676D1 (de) 2008-10-23
JP2007031867A (ja) 2007-02-08
TWI298668B (en) 2008-07-11
TW200704490A (en) 2007-02-01
CN1904196B (zh) 2010-06-09

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